Fan housing and assembly method

ABSTRACT

A fan assembly and associate methods are shown. Fan assemblies are shown having one or more components, where a location of the components is adjustable with respect to a base. In one example the components can be located at a specified distance from a motor shaft for a number of different motor sizes.

TECHNICAL FIELD

Embodiments described herein generally relate to fan assemblies. Specific examples may include industrial fan assemblies, such as plenum fans.

BACKGROUND

In the industry of industrial fans, there are numerous configurations that may be used to fit certain customer needs. This can result in a challenging manufacturing process requiring large numbers of different components that are needed to manufacture all of the various configurations of fan assemblies. Improved in fan assemblies and methods or manufacturing fan assemblies are desired.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a fan assembly in accordance with some embodiments of the invention.

FIG. 2 is an isometric view of foot assembly of a fan assembly in accordance with some embodiments of the invention.

FIG. 3 is a side view of a fan assembly in accordance with some embodiments of the invention.

FIG. 4 is a side view of another fan assembly in accordance with some embodiments of the invention.

FIG. 5 is flow chart of a method of manufacture in accordance with some embodiments of the invention.

DESCRIPTION OF EMBODIMENTS

The following description and the drawings sufficiently illustrate specific embodiments to enable those skilled in the art to practice them. Other embodiments may incorporate structural, logical, electrical, process, and other changes. Portions and features of some embodiments may be included in, or substituted for, those of other embodiments. Embodiments set forth in the claims encompass all available equivalents of those claims.

FIG. 1 shows a fan assembly 100 according to an example of the invention. The fan assembly 100 includes a motor 110 and an impeller 112. Examples of motors 110 include electric motors such as DC or AC motors, however other motors such as hydraulic motors, etc, are within the scope of the invention. Although FIG. 1 shows a centrifugal impeller, having a number of blades 114, the invention is not limited to centrifugal impellers. Examples of the invention may also be used with axial impellers, and/or mixed flow impellers. Although a plenum fan assembly 100 is shown as an example, configurations of the present invention may also be used with other types of fans.

The fan assembly 100 includes a support frame 120 to hold the motor 110, which in turn holds the impeller 112. In the example shown, the support frame 120 includes a number of components. The number of components shown in FIG. 1 includes a motor mount 126. In the example shown, a pair of bottom rails 122 are coupled to a pair of cross members 124 to form a lower portion of the support frame 120. In one example, the rails include box section rails. In one example box section rails add stiffness to the support frame without adding significant weight. Although rails are shown as an example, other structural members apart from rails, such as formed metal sheet, or other configurations are also within the scope of the invention.

In the example of FIG. 1, the lower portion of the support frame 120 is coupled to an upper portion 128 of the support frame 120. In the example shown, the rails 122 are integrally formed with the upper portion 128 of the support frame 120 from a single sheet of metal, such as steel. In other examples, the upper portion 128 of the support frame 120 may be formed separately and joined to the rails 122 using welding, fasteners, or other suitable attachment techniques.

In one example the collection of components, including rails 122, rails 124, the motor mount 126 and the upper portion 128 of the support frame 120 are fixed with respect to one another, and form a base, such that a number of adjustable components may be positioned with respect to the base.

As noted above, in the example of FIG. 1, the number of components further includes a number of adjustable components. In one example the number of adjustable components includes an inlet plate 130 that is adjustable with respect to the base. In the example shown, an inlet funnel 134 may be coupled to the inlet plate 130. In the example shown, the inlet plate 130, and the attached inlet funnel 134 are adjustable with respect to the base. In one example the number of adjustable components includes one or more mounting feet 140. In one example the number of adjustable components includes one or more thrust isolator brackets 150.

A number of advantages are provided in configurations including a number of adjustable components. As described in more detail below, a smaller number of components can be used for a variety of fan assembly configurations. For example, by adjusting individual components during manufacture, a number of substantially identical components can be arranged to fit a number of different motor sizes. This simplifies manufacturing by reducing a number of components that need to be on hand to assemble various different configurations of fan assemblies.

FIG. 2 shows a mounting foot 140 according to an embodiment of the invention. A fixed portion 142 is mounted to the support frame 120, and a movable portion 144 is adjustable within a range of vertical motion indicated by arrow 148. Although vertical adjustability is described in the present examples, other ranges of adjustability, such as horizontal adjustability or diagonal adjustability are also within the scope of the invention.

In one example, markings 146 are included on one or more of the components of the support frame 120 to indicate a location within the range of vertical motion. In one example, markings 146 are included on both the fixed portion 142 and the movable portion 144. In one example, the markings 146 include indented features that are stamped, etched, or otherwise formed into a metal portion of one or more of the components. In one example, the markings include mating indents that click the movable portion 144 into one of several available discrete vertical location within the range of vertical motion.

In one example, mating indents are used to hold the movable portion 144 in place until a weld or other fastener can more permanently secure a location of the movable portion 144 for a given configuration, such as a selected motor size. In one example, fasteners such as rivets, swage locks, screws, bolts, etc. are used to join components of the support frame 120. In one example, the components are joined using other methods, such as adhesives, or welding.

FIGS. 3 and 4 illustrate how a number of adjustable components as described above can be used to assemble at least two different fan assemblies with different motor sizes, using substantially identical components.

The fan assembly 102 is shown in FIG. 3 with a first motor 110A having a first size, while the fan assembly 104 is shown in FIG. 4 with a second motor 110B having a second motor size that is smaller than the first size of motor 110A. In one example, a motor rotation axis is used as a datum to locate adjustable components in each fan assembly 102, 104. The first motor 110A is shown with a first motor rotation axis 111A, while the second motor 110B is shown with a second motor rotation axis 111B.

In FIG. 3, one or more of the mounting feet 140 are adjusted within ranges 141 to provide a distance 113A with respect to the first motor rotation axis 111A. In the example shown, the movable portion 144 of each mounting foot 140 is adjusted with respect to the fixed portion 142 of the mounting foot 140. As described above, in one example, markings are used to easily select an appropriate location within the range 141. In one example the markings indicate a motor type, and are therefore easy for a technician to use when assembling the fan assemblies 102, 104. The technician merely needs to look at the motor type being used, and select the appropriate marking in the range 141 to position the movable portion of each mounting foot 140.

In the example of FIGS. 3 and 4, the inlet plate 130 is also adjustable to center the inlet funnel 134 on the first motor rotation axis 111A. In the example shown, the inlet plate 130 is adjusted with respect to the upper portion 128 of the support frame 120. As described above, fixed components, such as rails 122, rails 124, the motor mount 126 and the upper portion 128 of the support frame 120 are fixed with respect to one another, and form a base, such that adjustable components, such as the inlet plate 130, may be positioned with respect to the base. In one example, markings 166 are used to easily select an appropriate location of the inlet plate 130 within a range 131. As in the mounting feet example, in one embodiment, the markings may include a motor type to more easily select a location within the range 131.

The examples of FIGS. 3 and 4 further include one or more thrust isolator brackets 150. The one or more thrust isolator brackets 150 are also adjustable to center a thrust isolator bracket 150 on the first motor rotation axis 111A. In other examples, thrust isolator brackets 150 may not be used. In the example shown, one or more thrust isolator brackets 150 are adjusted with respect to the upper portion 128 of the support frame 120. As described above, fixed components, such as rails 122, rails 124, the motor mount 126 and the upper portion 128 of the support frame 120 are fixed with respect to one another, and form a base, such that adjustable components, such as thrust isolator brackets 150, may be positioned with respect to the base. In one example, markings 156 are used to easily select an appropriate location of the thrust isolator brackets 150 within a range 151. As in the mounting feet and inlet plate examples, in one embodiment, the markings may include a motor type to more easily select a location within the range 151.

In the example of FIG. 4, as noted above, a second motor 110B is used that is smaller than the first motor 110A. Despite the difference in motor size, FIG. 4 shows the one or more of the mounting feet 140 adjusted within ranges 141 to provide a distance 113B from the second motor rotation axis 111B. Because of the adjustability of the one or more of the mounting feet 140, the distance 113B is substantially identical to the distance 113A. In this way both fan assemblies 120 and 104 can be used in a similar end user application with a motor rotation axis (111A, 111B) being centered, or otherwise consistently located within a fan space.

Further, despite the difference in motor size, FIG. 4 shows the inlet plate 130, and its associated inlet funnel 134 centered on the second motor rotation axis 111B. In FIG. 4, the inlet plate 130 is located lower on the upper portion 128 of the support frame 120 by distance 133. Likewise, despite the difference in motor size, FIG. 4 shows the one or more thrust isolator brackets 150 centered on the second motor rotation axis 111B.

Notably in both FIGS. 3 and 4, substantially identical base components (rails 122, rails 124, the motor mount 126 and the upper portion 128 of the support frame 120) and adjustable components (mounting feet 140, inlet plate 130, and thrust isolator brackets 150) are used to assemble the two different configurations of fan assemblies 120, 104. Because of the adjustability, as described above, different motor sizes such as motor 110A and 110B can be accommodated using the substantially identical support frame components.

FIG. 5 shows a method of manufacturing a fan assembly according to examples such as the examples described above. In operation 502, a first motor is selected, the first motor having a first motor size. In operation 504, the selected motor is mounted to a support frame base. In operation 506, an impeller is attached to a motor shaft of the first motor. In operation 508, a plurality of components are attached to the support frame base. In one example, attaching the plurality of components includes attaching a faceplate, wherein a faceplate location is centered on the motor shaft of the first motor. In operation 510, a second fan assembly is formed having a different motor size, using a substantially identical support frame base and a substantially identical plurality of components. As described in examples above, as a result of adjustability, locations of the plurality of components on the support frame are different than in the first fan assembly, and are placed with respect to the different motor size.

To better illustrate the method and apparatuses disclosed herein, a non-limiting list of embodiments is provided here:

Example 1 includes a fan assembly. The fan assembly includes a motor, having a motor shaft, an impeller coupled to the motor shaft, and a support frame coupled to the motor. The support frame includes a base, having a motor mounting surface, and a number of components, mountable to the base, wherein a location of the components is adjustable with respect to the base to locate the components at a specified distance from the motor shaft for a number of different motor sizes.

Example 2 includes the fan assembly of example 1, further including markings to indicate a vertical location of the components within a pre-selected range.

Example 3 includes the fan assembly of any one of examples 1-2, wherein the markings include indented features in a metal portion of the support frame and the components.

Example 4 includes the fan assembly of any one of examples 1-3, wherein the number of components includes an inlet plate.

Example 5 includes the fan assembly of any one of examples 1-4, wherein the number of components includes one or more mounting feet.

Example 6 includes the fan assembly of any one of examples 1-5, wherein the number of components includes one or more thrust isolator brackets.

Example 7 includes a fan assembly. The fan assembly includes a motor, having a motor shaft, an impeller coupled to the motor shaft, and a support frame coupled to the motor. The support frame includes a base, having a motor mounting surface, a number of components, attached to the base, and a number of markings on the base and the number of components to locate the components at a specified distance from the motor shaft for a number of different motor sizes.

Example 8 includes the fan assembly of example 7, wherein the number of markings are indented features in a metal portion of the support frame and the components.

Example 9 includes the fan assembly of any one of examples 7-8, wherein the impeller is a centrifugal impeller.

Example 10 includes the fan assembly of any one of examples 7-9, wherein the number of components includes an inlet plate.

Example 11 includes the fan assembly of any one of examples 7-10, wherein the number of components includes one or more mounting feet.

Example 12 includes the fan assembly of any one of examples 7-11, wherein the number of components includes one or more thrust isolator brackets.

Example 13 includes a method of making fan assemblies. The method includes forming a first fan assembly, including selecting a first motor having a first motor size, mounting the selected motor to a support frame base, attaching an impeller to a motor shaft of the first motor, and attaching a plurality of components to the support frame base, including attaching a faceplate, wherein a faceplate location is centered on the motor shaft of the first motor. The method includes forming a second fan assembly having a different motor size than the first motor size, using an identical support frame base and an identical plurality of components, wherein locations of the plurality of components on the support frame are different than in the first fan assembly, and are placed with respect to the different motor size.

Example 14 includes the method of example 13, wherein attaching a plurality of components to the support frame base includes aligning markings between the components and the support frame base wherein the markings correspond to the selected motor.

Example 15 includes the method of any one of examples 13-14, wherein attaching a plurality of components includes attaching a number of mounting feet to the support frame base, wherein a distance from each mounting foot to the motor shaft is substantially the same in the first fan assembly and the second fan assembly.

Example 16 includes the method of any one of examples 13-15, wherein attaching a plurality of components includes attaching a thrust isolator bracket to the support frame base, wherein the thrust isolator bracket is centered on the motor shaft in the first fan assembly and the second fan assembly.

Example 17 includes the method of any one of examples 13-16, wherein attaching a number of components to the support frame base includes welding.

Example 18 includes the method of any one of examples 13-17, wherein attaching a number of components to the support frame base includes attaching a fastener between the number of components and the support frame base.

The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “examples.” Such examples can include elements in addition to those shown or described. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. §1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. 

1. A fan assembly, comprising: a motor, having a motor shaft; an impeller coupled to the motor shaft; a support frame coupled to the motor, wherein the support frame includes; a base, having a motor mounting surface; and a number of components, mountable to the base, wherein a location of the components is adjustable with respect to the base to locate the components at a specified distance from the motor shaft for a number of different motor sizes.
 2. The fan assembly of claim 1, further including markings to indicate a vertical location of the components within a pre-selected range.
 3. The fan assembly of claim 2, wherein the markings include indented features in a metal portion of the support frame and the components.
 4. The fan assembly of claim 1, wherein the number of components includes an inlet plate.
 5. The fan assembly of claim 1, wherein the number of components includes one or more mounting feet.
 6. The fan assembly of claim 1, wherein the number of components includes one or more thrust isolator brackets.
 7. A fan assembly, comprising: a motor, having a motor shaft; an impeller coupled to the motor shaft; a support frame coupled to the motor, wherein the support frame includes; a base, having a motor mounting surface; a number of components, attached to the base; and a number of markings on the base and the number of components to locate the components at a specified distance from the motor shaft for a number of different motor sizes.
 8. The fan assembly of claim 7, wherein the number of markings are indented features in a metal portion of the support frame and the components.
 9. The fan assembly of claim 7, wherein the impeller is a centrifugal impeller.
 10. The fan assembly of claim 7, wherein the number of components includes an inlet plate.
 11. The fan assembly of claim 10, wherein the number of components includes one or more mounting feet.
 12. The fan assembly of claim 11, wherein the number of components includes one or more thrust isolator brackets.
 13. A method of making fan assemblies, comprising: forming a first fan assembly, including: selecting a first motor having a first motor size; mounting the selected motor to a support frame base; attaching an impeller to a motor shaft of the first motor; attaching a plurality of components to the support frame base, including attaching a faceplate, wherein a faceplate location is centered on the motor shaft of the first motor; and forming a second fan assembly having a different motor size than the first motor size, using an identical support frame base and an identical plurality of components, wherein locations of the plurality of components on the support frame are different than in the first fan assembly, and are placed with respect to the different motor size.
 14. The method of claim 13, wherein attaching a plurality of components to the support frame base includes aligning markings between the components and the support frame base wherein the markings correspond to the selected motor.
 15. The method of claim 13, wherein attaching a plurality of components includes attaching a number of mounting feet to the support frame base, wherein a distance from each mounting foot to the motor shaft is substantially the same in the first fan assembly and the second fan assembly.
 16. The method of claim 13, wherein attaching a plurality of components includes attaching a thrust isolator bracket to the support frame base, wherein the thrust isolator bracket is centered on the motor shaft in the first fan assembly and the second fan assembly.
 17. The method of claim 13, wherein attaching a number of components to the support frame base includes welding.
 18. The method of claim 13, wherein attaching a number of components to the support frame base includes attaching a fastener between the number of components and the support frame base. 